BATCH & CONTINUOUS DRYING - Vekamaf Micron drying... · DRYING TECHNOLOGIES SELECTING THE RIGHT...

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BATCH & CONTINUOUS DRYING PROCESS TECHNOLOGIES FOR TOMORROW SM

Transcript of BATCH & CONTINUOUS DRYING - Vekamaf Micron drying... · DRYING TECHNOLOGIES SELECTING THE RIGHT...

Page 1: BATCH & CONTINUOUS DRYING - Vekamaf Micron drying... · DRYING TECHNOLOGIES SELECTING THE RIGHT DRYER When selecting the right drying equipment, it is important to take a number of

BATCH & CONT INUOUS DRYING

P R O C E S S T E C H N O L O G I E S F O R T O M O R R O WSM

Page 2: BATCH & CONTINUOUS DRYING - Vekamaf Micron drying... · DRYING TECHNOLOGIES SELECTING THE RIGHT DRYER When selecting the right drying equipment, it is important to take a number of

CONTENTS

ABOUT HOSOKAWA MICRON B.V. 2

DRyINg TeCHNOlOgIeS 4

FLASH DRYING 6

VACUUM DRYING 14

FREEZE DRYING 22

PROCeSS AUTOMATION CONTACT 24

SeRVICe & SUPPORT 26

TeSTINg & TOllINg 28

INDUSTRIeS

FOOD INDUSTRY 30

PHARMACEUTICAL INDUSTRY 32

CHEMICAL INDUSTRY 34

MINERALS & METALS INDUSTRY 36

CONTACT 38

P R O C E S S T E C H N O L O G I E S F O R T O M O R R O W

ABOUT HOSOKAWA MICRON B.V.

Hosokawa Micron B.V. is specialist in the design, manufacture and supply of powder

processing systems and equipment for the mechanical and thermal processing of dry and

wet powders. Located in Doetinchem in The Netherlands, Hosokawa Micron B.V. is expert

in mixing, drying and agglomeration.

Hosokawa Micron B.V. was established in 1987 as a result of a merger between Nautamix

in Haarlem (founded in 1923), Machinefabriek Vrieco in Zelhem (founded in 1939) and

ISEM in Doetinchem (founded in 1928). In 2000 Schugi (founded in 1958) was merged into

the company. Today, Hosokawa Micron B.V is one of the main parent companies within

the Hosokawa Group.

MISSION STATEMENT

Hosokawa Micron B.V. is a leader in offering technological know-how and solutions in the

field of mixing, drying and agglomeration. By our professionalism, service orientation and

dedication we help clients to achieve their goals, or even exceed them. In doing so we

achieve long-term relationships with both clients and suppliers as well as an attractive

return for our shareholders.

We offer a challenging and motivating work environment for our employees and want to

contribute to a sustainable society.

Agglomeration

MixingDrying

FoodPharmaceutical

Minerals & metalsChemicals

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D R Y I N G T E C H N O L O G I E S

SELECT ING THE R IGHT DRYER

When selecting the right drying equipment, it is important to take a number of factors into

account. There are the properties of the feed material to consider, like moisture content,

consistency, particle size and distribution, temperature resistivity and porosity. The quantity

of the feed material is also important and will help determine the need for batch or

continuous operation. Moreover, for products that are toxic, explosive or run the risk of

oxidisation, there is a need for closed-circuit operation.

Additional factors to consider include specific requirements for final product quality, size,

shape and moisture content; the production environment, the permitted construction

materials, the availability of energy resources and energy consumption.

Make the most of our expertise and make selecting the right dryer, easy.

GREEN EFFICIENCY!

With the effects of global warming and pollution on energy prices and the environment,

saving energy is becoming ever more important. In fact, the best way to save energy is

by drying the feed material mechanically using, for example, filtration, centrifugation or

sedimentation. This will remove as much of the solvent as possible before starting the

thermal drying process.

The next stage is to select a thermal drying process that uses a minimal amount of

energy and one that takes energy recovery into account using heat pumps, vapor flow

recompression or superheated steam for example.

Hosokawa Micron can help you select the right drying process to do just that: save

energy. Our experienced engineers are more than happy to give you the advice you need.

CHALLENGE US TO SOLVE YOUR DRYING PROBLEMS!

Bulk pharmaceuticals

Polymers

Catalysts

CeramicsFlavours

Injectables

Metal powders

Agrochemicals

Food ingredients

Mineral fillers

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Hosokawa Micron’s flash drying technology has been developed to combine drying,

de-agglomeration/milling and classifying technology in one piece of equipment.

The Micron Dryer flash dryer (MDH) is in continuous development and was the first

drying system of its type to be patented worldwide. The latest version of this

flexible drying technology is the Drymeister (DMR), a state of the art technology.

Its unique design makes it suitable for drying numerous different materials with a

wide range of different properties. It can handle fluctuating moisture content from

a few per cent to more than 80 per cent. The Drymeister is ideal for:

• Suspensions

• Slurries

• Pastes & dough

• Filter cakes

• Wet powders

Key benefits of this unique technology are its efficiency, reliability and low

maintenance/operational costs. Moreover, it can be used to achieve different

fineness varying from D97 = 250 µm down to D50 in nm in the case of wet milling,

depending on the upstream process. In combination with wet milling, the

Drymeister is able to produce extremely high-end fineness.

Working principle

The wet material is fed through different specially-designed feeding

systems (1) into the grinding (2) and drying (3) sections of the dryer’s

main body. The impact energy imparted by the grinding rotor disperses

the wet material into very fine particles.

A temperature-controlled, hot, gas stream coming from the air heater

(4) is drawn by the exhaust fan through the main body and fluidises the

fine particles in the grinding chamber. This guarantees optimal heat

exchange and instant evaporation of moisture.

The dried particles are conveyed with the gas stream to the top section

of the dryer where a separator (5) classifies the particles by weight.

Particles which are too coarse or too wet return to the lower sections.

Particles passing the classifier at the set cut point are conveyed with the

exhaust air (6) to a powder-air separating system like a cyclone or

cyclone filter in combination with cyclone scrubbers for example.

A fluidised bed of product in the drying chamber ensures a low level of

adhesion of un-dried material on the inside wall of the drying chamber.

By changing process parameters like the classifier speed, the outlet

temperature, the moisture content and the particle size of the end

product can be adjusted and controlled.

Micron Dryer & Drymeister®

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Model types

The main difference between our different flash dryer models

is situated in the dispersion/milling section. Depending on the

texture of the feed and the required final product properties,

various dispersion mechanisms can be used. The three most

important ones are:

Bar-disc rotor

New-blade rotor

TT hammers

Flow sheet of an open flash drying system

1 Product in / agitated hopper

2 Dosing screws

3 Drymeister (DMR)

4 Filter

5 Fan

6 Silencer

7 Direct heater

8 Inlet filter

9 Product out

10 Control cabinet

1. Drymeister Bar-Disc type rotor

A strong impact and air turbulence is generated by a high

speed dispersion rotor, called the bar-disc rotor: with a

maximum tip speed of 110 m/s. This rotor is used for drying

more solid materials with moisture such as filter cake.

2. Drymeister Blade type rotor

This rotor is used to handle sticky and more liquid dispersions.

The rotor ensures a perfect dispersion of the feed material

into the hot air stream.

3. MDH type rotor

A horizontally driven grinding rotor with TT hammers takes

care of a combination of milling and drying. The impact on

the particles is significantly higher compared to the Drymeister

(DMR).

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Typical Processes/Applications

Our flash drying technologies are suitable for a large variety of applications which in

turn means an extensive number of factors to take into consideration when selecting

the right type: product consistencies, nature of the raw materials: particle size distri-

bution, moisture content etc.; the liquids to be evaporated, temperature and so forth.

This is why we like to work closely with our clients to find out what would be the most

suitable flash drying system for you.

Using our practical engineering expertise and process know-how, we can design and

engineer the perfect continuous flash drying system to meet your specific process and

end-product requirements.

Below you will find two examples of process applications, one open and one closed

system, and considerations that need to be taken into account when selecting

a flash dryer:

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Human food grade flash drying installation for organic / thixotropic materials

1 Product in / agitated hopper

2 Dosing pump

3 Drymeister (DMR)

4 Cyclone

5 Fan

6 Scrubber

7 Indirect heat exchanger

8 Inlet filter

9 Product out

10 Control cabinet

1. Open system (drying food)

Organic materials used in food often require special processing systems to handle

their specific characteristics. Safety aspects due to the risk of explosion and/or auto-

ignition need to be taken into consideration during the engineering of such systems.

In addition to the risks related to the handling of such products, hygienic design and

construction aspects are essential.

Depending on the final use of the dried powders, bacteria levels have to be kept

under control. This might require the engineering of wetting or cleaning-in-place

systems al well.

2. Closed system (drying chemicals in inert gas atmospheres)

When chemical materials that are explosive or contain solvents for example have to be processed, the Drymeister can be

designed to operate using an inert atmosphere. When operating using an inert gas or a closed loop system, we can also

evaluate the benefits of a heat recovery system.

Operational costs of drying systems are of high

importance especially when you are processing

low-cost products. It can be economical to recover

the heat contained in the outlet gas from the fan,

in order to reduce the plant’s operational costs.

Several heat recovery systems can be applied

depending on the process conditions:

• Gas/gas heat exchanger

• Warm gas directly re-introduced

to the burner

• Warmwaterproduction

1 Product in / agitated hopper

2 Dosing screws

3 Drymeister (DMR)

4 Filter

5 Solvent recovery

6 Fan

7 Indirect heat exchanger

8 Product out

9 Control cabinet

Chemical flash drying installation for materials containing solvents

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Complete systems

Hosokawa Micron has been installing its Micron Dryers and Drymeister flash drying

systems all over the world for more than 40 years. Extensive experience and know

how of drying processes enables us to design, manufacture and install complete

drying systems, as well as all of the necessary ancillaries. Below you will find an

overview of some key system components.

1. Feeding systems

Feeding a dryer is an integral part of the drying system, ensuring a constant feed

rate. Hosokawa Micron offers reliable feeding systems to ensure optimal efficiency

of the drying process and excellent end-product consistency.

Typical feeding systems:

This type of feeder comes in several

variations, for example: single or double

shaft with full or open flights, paddle or

ribbon; heated versions are also available

for materials with a dough-like consistency.

The type of pump depends on the appli-

cation; e.g.: screw, diaphragm or hose. The

feeder itself is often combined with a

feeding hopper.

These are designed to handle product

with easy-flowing characteristics and are

available in a wide range of dimensions.

These feeders can also be heated to

increase the drying efficiency, to improve

the feeding or to avoid bacterial growth

when working with food.

Specially-designed feed hoppers with various

agitators guarantee a constant feed of wet

material above the feeder for accurate feed

to the dryer. For larger volumes or thixotropic

feed materials for example, we would

recommend specifically-designed screw cone

hoppers.

Direct heaters (up to 650ºC inlet)

• Gas burner

• Oil burner

• Electric heater

• Hot gas from other sources

Indirect heaters (up to 450ºC inlet)

• Steam heat exchanger

• Thermo-oil heater

• Indirect gas heater

It could be worthwhile considering a combination of heat sources

depending on your site utilities or your global location. Typical

combinations are:

• Steam + oil

• Steam + electric

It is possible to filter incoming heat media before heating, using

different types of filters. This will provide clean process gas when it is

required.

3. End product recovery

There are several solutions to choose from for collecting the fine

powder after drying. Product characteristics like fineness, density,

temperature, explosivity/flammability and process parameters like

the material/gas concentration are important considerations when

selecting the right solution.

•Filter

The simplest solution is when the product and the gas go directly

into the filter.

•Cyclone+filter

When cleanability is important we recommend adding a powder-

air separating system like a cyclone before the material/gas

mixture is conveyed into the filter.

•Scrubber

When handling organic materials where auto-ignition is a risk,

we recommend adding a wet scrubber after the dry filter.

Screw feeders

Pumps Static feed hoppers

Agitated feed hopper

2. Heating systems

A gas heater is necessary for the supply of hot gas to the dryer. The heater includes a temperature control system to maintain a constant

gas temperature at the dryer outlet. Types of gas heaters we would recommend are:

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Drymeister models and evaporation capacities

Key features

Easy access

Either for cleaning, inspection or maintenance inside the dryer,

the Drymeister offers the best accessibility, whatever size you

may choose.

Ultra fine regular end product

Due to its specially-designed dispersion rotor, the Drymeister is

able to produce fine or ultra-fine powders in one step from

suspensions, slurries, pastes and dough, filter cakes and wet

powders.

High evaporation capacity

Due to the combination of high ∆T with a good dispersion of the

wet product in the gas, the Drymeister can evaporate large

quantities of liquid, such as water.

Low energy consumption

Open loop, closed loop or gas recycle system: depending on the

chosen system, various levels of energy savings can be achieved.

Low maintenance

EfficiencyCompact design

Extremely high end fineness

Reliability

High evaporation capacity

Models & specifications Drymeister flash dryers are available in 7 models. Underneath you will find their basic specifications. Details on MDH models can be provided on request.

Model

Height [mm]

Length [mm]

Width [mm]

Max. power grinding motor [kW]

Min./max. power separator motor [kW]

Max. volume outlet air 80 °C [m3/min]

Evaporated water at ∆T=150 °C [kg/h]

Evaporated water at ∆T=200 °C [kg/h]

Evaporated water at ∆T=300 °C [kg/h]

Evaporated water at ∆T=400 °C [kg/h]

Evaporated water at ∆T=500 °C [kg/h]

Model 1

1,940

1,400

700

11

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25

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103

148

189

226

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3,000

1,700

1,200

22

1.5/11

50

158

206

296

378

452

Model 3

3,300

2,300

1,500

45

2.2/15

100

316

412

592

756

904

Model 4

3,600

2,400

1,600

90

5.5/30

200

632

824

1,184

1,512

1,808

Model 6

5,000

4,500

2,600

280

22/55

600

1,896

2,472

3,552

4,536

5,424

Model 5

4,500

3,600

1,600

200

11/45

400

1,264

1,648

2,368

3,024

3,616

Model 7

5,500

5,000

3,200

355

30/75

800

2,528

3,296

4,736

6,048

7,232

L x W

H

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Drying is responsible for more than 15% of the energy used in modern industrial

processes. This makes energy efficiency a major factor to be considered when

designing a vacuum drying system. At Hosokawa Micron, we are expert in the

development of such state-of-the-art drying technologies and put a lot of

thought into developing systems that save you energy.

When it comes to our vacuum drying systems, we have technology that is

capable of handling materials such as wet powders, filter cakes, pastes and

slurries, especially those products that are heavy, sticky, heat sensitive; that

contain solvents, are toxic or even explosive. Our vacuum dryers are suitable for

low vacuum operation and can also be applied to other phases in the process,

for example:

•Reaction/crystallisation

•Heating/cooling

•Sterilisation

•Liquid/solidseparationandde-aeration

Our Vrieco-Nauta® conical screw vacuum dryer was one of the first agitated

vacuum dryers developed and was designed to replace the vacuum tray dryer.

Now we have an even broader range of vacuum drying systems for the

treatment of an even wider number of media, from chemicals and metals to

pharmaceuticals.

Working principle

1. Heat energy is transferred into the product through a jacketed vessel

wall causing solvents or moisture residues to evaporate.

2. A rotating agitator (e.g. screw, ribbon or paddle) transports the

product along the vessel wall and helps the vapours to escape to the

surface providing a frequent exchange of particles in contact with

the heated surface at the same time.

3. A vacuum system keeps the vessel under constant vacuum and

removes the vapours from the vessel, having separated dust particles

from the vapours in a dust filter on top of the vessel first. The

vacuum within the vessel also reduces the saturated vapour pressure

of the solvent, facilitating drying at much lower temperatures.

4. For recovery of solvents, a condenser can be installed in combination

with a collection vessel. The drying time and the drying process are

dependent on heat conduction of the solid particles and solvents,

pressure and temperature conditions as well as the speed of the

agitator.

Vacuum Dryers

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Choosing the right rotor

One of the most important design aspects of a vacuum dryer is its agitator. In order to

choose the right agitator with the right characteristics, it is essential to understand what

the properties of the feed material are and what you expect from the vacuum drying

process.

Screw agitator

The screw agitator is a well-proven design suitable for drying powders, filter cakes, pastes

and slurries under atmospheric or vacuum conditions. It is suitable for almost all products

even when they are sticky. With its excellent product transportation along the vessel wall,

it guarantees an efficient drying cycle and can be applied for dryers with capacities of over

20,000 litres.

Paddle agitator

When products are not likely to stick, a paddle agitator can be used to provide optimal

temperature control and to transport product between the rotor tip and the vessel wall.

When required, it can also be used to mix the products intensively after the drying cycle.

Ribbon agitator

When products have low-starting moisture content and good flow, a ribbon agitator can

provide an alternative solution to the screw agitator. It can agitate a larger batch at any

one time, resulting in better heat transfer and possibly shortening drying time.

Screw agitator

Ribbon agitator

Paddle agitator

Conical paddle dryer

1 Vacuum dryer

2 Product in

3 Vacuum filter

4 Condenser

5 Receptacle

6 Vacuum pump

7 Heating/cooling skid

8 Product out

9 Control Cabinet

10 Operating Panel

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Conical Screw dryer

Vacuum drying installation with one condensation step

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Typical Applications

Using our practical engineering expertise and process know-how, we can design and

engineer the most suitable vacuum drying system to meet your process and end-

product requirements. Below, you will find two examples of typical applications,

followed by an example of Hosokawa Micron’s continuing Research & Development

for its vacuum drying technologies.

1. Vacuum drying in the chemical industry

Drying at low temperatures and deep vacuum levels in the chemical industry is

becoming more and more important due to increasingly stringent requirements.

Chemical products like polymers, pigments, toners and agro chemicals are

produced in large quantities and capacities, which need to be dried under vacuum

conditions and are often heat sensitive. This means that hotspots, localised heat

input, bearings or localised structural supports inside the vessel need to be avoided.

Hosokawa Micron has invested in continuing research and engineering for the

development of vacuum vessels and agitators for this kind of application. The sizes

of the vacuum dryers we can fabricate is always growing and we work with

cantilevered agitators that are no longer supported at the bottom of the vessel.

This improves the flexibility of our dryers even further when it comes to handling

slurries, pastes and powders to low end-moistures.

Smart engineering:

In the last couple of years, Hosokawa Micron

has developed their vacuum dryer in a multi-

purpose piece of equipment capable to

perform much more tasks than only drying

at low temperature.

Different chemical and crystallisation

reactions as well as thermal and/or pressure

treatments such as steam stripping and

vacuum sterilization are being performed in

vacuum dryers.

In some cases, solid/liquid dewatering can be

realised prior to a drying stage. This can be

of interest to improve the cycle efficiency.

This step is possible by installing dewatering

filters in the outlet valve or in the vessel

depending on the product characteristics.

2. Aseptic and sterile process in the pharmaceutical industry

When dealing with active pharmaceutical ingredients, equipment needs to be

sterile and aseptic. Our dedicated pharmaceutical department has extensive

experience with the requirements set by pharmaceutical concerns, and can

provide expert guidance for the design and engineering of your dedicated

processes.

Some aspects should be looked at very carefully taken into account how critical

they can be:

•Designofflangesandstaticseals

•Designofdynamicsealslikemechanicalseals

•Designandconceptofsampling

•Batterylimitandseparationofsterile/aseptic-nonsterileenvironment

•Sterilisationphilosophyandvalidation

Recovery of condensate and control of temperature at all critical spots inside

the process.

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1 Vacuum dryer

2 Product in

3 Vacuum filter

4 Condenser

5 Receptacle

6 Vacuum pump

7 Optional condenser

8 Optional receptacle

9 Heating/cooling skid

10 Product out

11 Control Cabinet

12 Operating panel

Vacuum drying installation with two condensation steps

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Complete systems

Hosokawa Micron has been installing vacuum dryers and vacuum drying systems all over

the world for many years. This extensive experience and know-how makes us experts in

the design, manufacture and installation of complete drying systems, including all of

the ancillary equipment imaginable. Here are some of the key components that we

engineer and manufacture.

1. Heating / cooling skid

Hosokawa Micron uses the latest advanced

3D drawing software for engineering skids

for indirect heating and cooling of our

vacuum drying systems. With these kinds of

skids, it is possible to heat or cool the

complete dryer and to cool the ancillaries,

like condensers. When required for reflux

processes, the top section of the dryer can

be cooled at the same time as the bottom

part is being heated.

2. Condenser / vacuum skid

To avoid large vacuum pump systems or

too many solvent emissions, a condenser

is placed in combination with a receptacle.

The condenser can be placed before and/

or after the vacuum pump, depending on

the liquid to be evaporated. Different

types of condensers can be used. Plate

exchangers are a good choice considering

their heat transfer and volume and

hairpin condensers are a preferred choice

when cleaning requirements are critical.

3. Heated agitator

The heat transfer surface plays an important role in the

efficiency of the vacuum drying process and a heated

agitator can be an interesting solution when products are

sticky or have demanding flow properties, or when specific

heat treatment is required. The heating medium in this

system is fed and returned to the agitator through the

hollow drive shaft of the gearboxes outside the vessel.

4. Inlet-Outlet ISEM™ ball segment valve

Hosokawa Micron has developed the unique ISEM ball segment valve as an in- and outlet valve for mixers and vacuum dryers.

This valve is gas, dust and liquid tight, has no flow resistance when opened and is easy to clean and access. The full bore

passage, the housing without static pockets and the sealing designs make it the best valve for applications where reliability of

the valve sealing is a key issue.

6. Controls

Our control systems consist of two automation systems:

•ProgrammableLogicController(PLC)tocontrolthe

vacuum dryer system

•Multi-panelforoperationofthevacuumdryersystem

without data acquisition and logging

Data acquisition and logging are subordinate to GAMP

and FDA standards and can be realised using a Distributed

Control System (DCS).

The ISEM valve has proven its reliability under difficult

conditions and is a very popular valve for process installations

using vacuum or pressure in combination with solvents or

toxic materials. The ISEM valve has also been adopted by

other machine manufacturers as an addition to their own

mixers, dryers and reactors.

Typical applications of the ISEM ball segment valve include:

•Chargeanddischargevalveformixers,dryers,sterilisation

systems and reactors

•Pre-dosingvalvesinpackingsystems

•Barriervalveinprocessinstallations

•Flip-flopvalvesforpowderdosinginpressuresystems 5. Filters

Our vacuum filters have been specially designed to

operate in conjunction with our Vrieco-Nauta® vacuum

dryers. The vacuum filter minimises pressure loss and in

most cases, the vacuum filter housing is welded on the

domed vessel cover. The filter is heated by means of a pipe

coil around the filter housing. Size and specifications

depend on product, solvent and the volume of vapours to

be handled. Automatic reverse jet cleaning systems are

standard and the filter body and cover are jacketed to

avoid condensation from the vapours passing through

the filter.

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Models & specifications

Hosokawa Micron vacuum dryers are available in many sizes, with batch volumes ranging from 1 liter up to 22,000 litres. Underneath you will find 7 sizes with their basic characteristics.

Model (water filling) [l]

Height (H) [mm]

Width (W) [mm]

Net volume (powder filling) [l]

Jacket surface area [m2]

Max. evaporation of water* [kg/h]

Max. evaporation of ethanol* [kg/h]

5

1,420

600

4.3

0.13

1

3

80

2,660

900

68

0.69

5

12.5

500

3,920

1,470

430

2.84

25

60

1,000

4,460

1,720

840

4.58

35

85

12,000

8,450

3,730

12,000

25

190

400

5,000

6,840

2,710

4,500

13

100

250

22,000

9,950

4,290

22,000

33

250

600

W

H

Key features

Fast drying times

With excellent product transportation along the vessel wall, Hosokawa

Micron´s vacuum dryers guarantee a faster and more efficient drying cycle.

Moreover, the quick and efficient removal of vapours results in dried solids

that are suitable for direct use. All of our specialists can assist you in the

selection of the most suitable technologies for your specific application and

product requirements.

Multipurpose

Hosokawa Micron’s vacuum dryers are very suitable for drying materials such

as powders, granules, pastes and slurries, especially when they are heavy,

sticky, brittle and/or heat sensitive. However, they are also suitable for vacuum

operation, reaction, heating, cooling and de-aeration.

Systems engineering

Hosokawa Micron strives to meet even the highest of client specifications and

provides solutions that comply with all of the relevant international standards

(FDA, cGMP, EHEDG). Our systems engineering encompasses automated solutions

with our patented CIP (Cleaning-In-Place) skids, SIP (Sterilization-In-Place) skids

and customised seal and mechanical seal designs, including sterile versions.

Fast drying times

SlurryPasteCIP/SIP

MultipurposeWet powders

Granules

Reliable

Low maintenance * with jacket surface temperature T=50°C

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Freeze drying (lyophilisation) has been used industrially for decades to preserve

foodstuffs and organic materials. However, traditional tray-type freeze dryers have

proven to be slow and labour intensive. The Hosokawa Active Freeze Dryer eliminates

these drawbacks and is a big step forward in the field of freeze drying bulk solids as

well as in powder technology in general.

Active Freeze Drying offers unique possibilities for turning a variety of materials into

a fine loose powder in just one single step. Material consistencies include:

•Solutions

•Dispersions

•Pastes

•Wetsolids

Efficiency, minimal handling and product quality are the key benefits of this new,

unique technology. Typical applications include pharmaceuticals like antibiotics,

proteins, collagens, API’s and electrolytes. Numerous successful applications are also

found in food and food additive applications like herbal extracts, milk derivatives,

enzymes, broth extracts, vegetables, lipids, insects, flavours, fibres, proteins and soups.

This new technology has also proven its suitability to the freeze drying of special

materials like nanomaterials, polymers, ceramics, pigments, fillers, lime stone, catalysts,

glass powder and salts.

Active Freeze Dryers

Freeze

dry

ing

Te

chn

olo

gy

Working Principle

In an Active Freeze Dryer, the product is first frozen dynamically in a specially-

designed chamber. Whether the material to be dried starts off as a liquid, granular

solid or paste, the movement inside the drying chamber ensures that it freezes quickly

in the form of free-flowing solid granules. Once the product is fully frozen, a deep

vacuum is applied and the sublimation starts. Heat applied to the vessel jacket is

effectively distributed throughout the product due

to the dynamic environment. The initially coarse,

frozen granules gradually shrink as the ice structure

connecting the frozen material sublimes, yielding a

loose powder consisting of fine, dry particles.

As the solvent disappears, the product temperature

starts to rise until it equals the jacket temperature.

This marks the end of the drying process. Once the

vacuum has been released, the chamber is opened

and the powdered product can be discharged.

Dryer Chamber

Powdered Dried Product

Heat VacuumProductCollector

SolventCondenser

Material to be dried Freezing medium

Model [l]

Max. net product volume [l]

Jacket surface area [m2]

Max. sublimation capacity at p=0.1 mbar [kg/h]

Max. sublimation capacity at p=2 mbar [kg/h]

1

0.7

0.06

0.2

0.1

5

3.5

0.13

0.5

0.3

60

45

0.69

2.6

1.7

120

85

1.02

3.9

2.6

1,000

750

4.58

17.6

11.4

500

370

2.84

10.4

7.2

800

600

3.93

15

9.9

Key features

Efficient and contamination-free

The Active Freeze Drying process is faster and less labour intensive than the traditional tray freeze drying process. This new process

produces lump free, free-flowing powders in one single step. Consequently, the handling is significantly shorter and simpler, and

perhaps more importantly: there is hardly any room for contamination which is ideal for sterile materials.

High Quality

Due to this alternative and much faster method of freezing the

substrate, the structure of the end product is different and in

the majority of cases, will result in an amorphous-like structure

with better redispersibility and free-flowing properties. In

addition to this, the particle size of the final product is often

extremely fine and uniform.

High product quality

Simple

Faster

Efficient

Less labor-intensiveFree-flowing powder

Compact

The Active Freeze Dryer is a compact piece of equipment that requires much less floor

space than conventional tray drying installations which usually comprise of horizontal

vessels, freezer and tray handling machinery. Hosokawa Micron has converted all of this

into a single vertical dryer.

Models & specifications

Our Active Freeze Dryers are available with vessels of 1 up to 1,000 litres. The basic characteristics of 7 different models are specified below.

API in tray dryer Same API in Active Freeze Dryer

PROCESS TECHNOLOGIES FOR TOMORROWSM22 23

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Pro

cess

Au

tom

atio

n

Process AutomationProcess automation is an inextricable part of every drying system, which is why

Hosokawa Micron has an experienced team of process and electrical engineers at hand

to help you identify the right degree of automation for your processes. Our engineers

are experts in translating process technology know-how into essential hardware and

essential software for optimum custom-made control solutions.

Qualification

Prior to the planning stage, our engineers will investigate the special demands of your

production sequence, the restrictions created by the supply network and the

environmental conditions in your production area (e.g. a potentially explosive

atmosphere, for example gas and/or dust). They will then systematically convert their

findings into a viable concept.

The diagram below illustrates the process that our engineers adopt for system

qualification.

Hardware

Selecting the correct hardware is essential for an efficient and reliable

production sequence. Our engineers combine safety, switching and operating

elements that best suit the production process and the environmental

conditions of your production site and incorporate these into your custom-

made control cabinet. It is inspected and tested before leaving Hosokawa

Micron’s manufacturing facilities in terms of functionality and quality and in

accordance to international IEC and EN standards.

Software

We then create a tailor-made software program that matches your process precisely, but is nevertheless flexible enough to allow

for quick and easy adaptations or process upgrades. The process control software is universally structured and documented. We use

tested program modules to avoid programming errors. These can be retrieved from libraries, permitting efficient program

generation for your process control unit.

Before the process control unit is delivered,

we carefully test the function of the software.

This means that you can concentrate fully on

process optimisation during the imple-

mentation, without having to worry about

any unwanted delays.

Process visualization

We have two different visualisation systems

available depending on your requirements.

For simple processes, we provide a Windows-

based operating and monitoring system.

For more complicated processes, we work

with state-of-the-art process visualisation

software.

User-friendly & reliable

Hosokawa Micron’s systems, hardware and software are all tried and tested. Our control solutions have been implemented

throughout a wide variety of industries. They are user-friendly, error-free and reliable, because we have reinvested the practical

experience gained from these implementations into the optimisation and improvement of our process technologies and our

automation controls.

User friendlyModular

Automation engineering

TailormadeReliable

Practical operation

Process visualization

URS

FS

SDS

HDS IQ

OQ

PQ

Installation

IQ-protocol

OQ-protocol

PQ-protocol

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Service & support

Serv

ice &

sup

po

rt

Downtime is unacceptable, which is why customers demand security and peace of mind

for their processes and service and support for their machinery. Hosokawa Micron can

pride itself on a highly-competent engineering department and a responsive and

smoothly operating service department.

On site services

•Preventativemaintenance

•Inspectionandtroubleshooting

•Repair&service

•Processsupportandoptimisation

•Modificationsandupgradingtolatesttechnology

•Internaltransport,relocationandconstruction

•OperatortrainingeitheronsiteorinDoetinchem,

The Netherlands

•Commissioning

•Certificationandvalidation

•Reconditioningofusedmachines

•Swapdrives

Preventative maintenance

Preventative maintenance means knowing that your production processes are in good working order and increasing the lifetime

of your plant. Hosokawa Micron has a dedicated team of experienced maintenance engineers specialised in just this: providing

on-site advice, engineering and training to help you optimise your processes. Our experienced engineers are focussed on identifying

potential mechanical, safety and process line problems before they cause unnecessary downtime.

Replacing old machinery with new

A retrofit, upgrade or refurbishment can be easier and more economical than specifying and buying new. Hosokawa Micron offers

exactly that: a combination of our high-quality products and spare parts with expert design and engineering as well as experienced

manpower. Our goal is to make sure you are left with equipment that performs at the same level as the brand-new equivalent.

Retrofitting

We will send in our expert engineers for an initial assessment, fix mechanical failures and replace broken parts. In short, we will give

your machines a new lease of life. Any new parts come with a 12-month guarantee but may well last another 25-30 years! That's what

we call value for money.

Upgrading

Our engineers can also help you improve production, increase capacity and

upgrade your existing processes to the latest industry standards. We can

minimise mechanical failures, convert to food-grade specifications and CIP

cleaning, all without necessarily having to replace the entire system.

Refurbishment

Refurbishment is more than a retrofit or upgrade. It's the whole package.

From start to finish, we will work with you to improve your processes: come

up with a plan, improve, repair, replace and upgrade whilst considering the

application, the market sector, industry standards and of course your wishes

and requirements.

Reliable24 hrs service & support

Repair

Predictable

Value for moneyUpgradeAvoid down-time

Improve Replace

Repair & maintenance

Our Technical Services Team carries out repair and maintenance services onsite or in our own fully-equipped workshop in Doetinchem, The

Netherlands, 24-hours a day, 7 days a week. This team comprises specialists in mechanical engineering, maintenance, instrumentation and

controls as well as process engineering.

Protect your investment

Create added security for your capital investment with one of our regular maintenance contracts. Our sales engineers will be more than

happy to discuss a bespoke agreement that meets your specific maintenance needs, either for single machines or entire process lines.

Spare Parts Service

Minimise the hassle of sourcing spare parts with our Spare Parts Service. We have a team of engineers on standby that can deliver the spare

parts and install them for you on site. And if that isn't efficient enough, we will happily discuss the options for your own in-house Hosokawa

Micron inventory: spare parts to hand, 24/7.

Service Department Hosokawa Micron B.V.

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Hosokawa Micron has its very own testing and development centre in Doetinchem, the

Netherlands. It offers unique possibilities for testing your product to determine the most

efficient process, system or plant prior to final design. We can provide laboratory as well

as production-sized trials.

Whether you wish to test a single machine or a complete powder processing system, the

same skilled and experienced staff are here to help ensure that your requirements are met,

and that you are entirely satisfied with the results.

We have test equipment at your disposal for:

•Batchvacuumdryingfrom5upto6,000litres

•Batchfreezedryingof1.5,5and60litres

•Continuousdrying

Is testing necessary?

If we could summarise the behaviour of powders in a set of rules and guidelines, in other

words, if results could be predicted, then testing would be unnecessary. Of course the

reality is somewhat different. Testing isn’t only necessary; it is the foundation of any

successful product or process.

At Hosokawa Micron, we enjoy helping our customers test their latest ideas and require-

ments and with our modern testing facilities, we can help you put theory into practice.

Testin

g &

Tollin

g

Toll processing & Contract manufacturing

Besides testing, we also offer a wide range of toll processing & contract manufacturing services ranging from single to multiple

processes, for batch and continuous drying.

Your advantages:

•Clearlydefinedcosts

•Noinvestmentinequipmentandbuildings

•Efficientproductionofsmallquantities

•Testyourprocessonalabandproductionscale

•Definethespecificationsofyourmachine

•Usetollprocessingaspartofyourdevelopmentprocess

•Producematerialsformarketingactivities,priortoinvestinginnewproductioncapacity

•Fillthegapbetweendesignandstartupofyournewequipmentorplant

•Launchnewproductsusingtollprocessing,untilyoursaleshavereachedasolidandprofitablebase

Rental equipment

Our testing centre is full-equipped with all of our latest equipment for operational trials but we also offer a range of rental

equipment so that you can carry out operational trials at your own facilities too. This means that you can fine tune process

parameters and monitor production flows prior to finalising equipment choices and process designs. To help things go smoothly,

our experienced process engineers will work closely with your engineering team to advise and develop the best solution for your

processing requirements.

Rental equipment

Testing

Toll processingContract manufacturing

Laboratory- and production scale trials

Testing & Tolling

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Hosokawa Micron’s drying systems offer quality and functionality, are easy to clean

and energy efficient. In the food sector, our drying equipment is used for the freeze

drying of food and feed products as well as related processes such as alkalisation,

sterilisation and pasteurisation. Additionally we have unique expertise regarding

freeze drying of food and feed products.

Food safety

Hosokawa Micron is an active participant in

the European Hygienic Engineering & Design

Group (EHEDG). This is a consortium of equip-

ment manufacturers, food industries, research

institutes and public health authorities whose

goal it is to increase food safety by improving hygienic engineering and design in all

aspects of food production. The long term benefit of this is not only improved product

safety, but also increased durability of equipment, reduced corrective maintenance and

consequently, lower operating costs. Likewise, Hosokawa Micron is able to engineer

and manufacture in accordance with 3-A sanitary standards.

Quality & functionality

By combining premium quality with optimal functionality, Hosokawa Micron’s equip-

ment can comply with the highest of international safety standards. All of our

machines and systems meet the requirements of highly-automated food manufacturing

including its most innovative processes.

Energy efficiency

Similarly, our wealth of experience and know-how in designing energy-efficient

solutions means that Hosokawa Micron’s dryers are some of the most environmentally-

friendly on the market.

Ind

ustrie

s

Applications and processes

•Continuousflashdryingofalginates&CMC

•Continuousflashdryingoffish&fishfeed

•Sterilisationofherbs&spices

•Freezedryingoffoodingredientslikegarlic,

algae, fruits & vegetables, etc.

•Freezedryingofplankton

•Freezedryingofmilkproducts

•Freezedryingofcolostrumandbreastmilk

•Alkalisation&dryingofcocoanibs

•Heattreatmentofstarchflour

•Pasteurisationofbabyfoodpowder

•Vacuumdryingofnutrients

Services

•Globalorganisationandsupport

•Processdevelopment

•Processtestingandvalidationinwell-equippedtestcentre

•Tollprocessingforproductbenchmarktestingbeforemarket

introduction

•Manufacturingsupportforscalingupproductionlevels

•HygienicsystemspossibleinaccordancewithEHEDG

guidelines and 3-A sanitary standards

Food industry

Cocoa

Fish feedHerbs & Spices

ChocolateFish meal

Alginate

YeastSweeteners

Natural Colorant

Fruits & VegetablesMeat proteins

OkaraFlavours

Fruits & vegetables

Fish

Herbs & spices

Cocoa

Vaporising liquids

Moneyinstead of

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Drying is an important part in the pharmaceutical production chain. It requires

extra-special care due to the sensitivity of the products, as well as strict organisation

and equipment that complies with the most stringent of industry standards.

Temperature, hazardous materials and sterility are just a few of the application’s

most vital considerations.

Developing new technologies

It is Hosokawa’s ambition to support its customers throughout the product life

cycle with technology that has been specially developed for some of the industry’s

most demanding applications. This is why we continue to invest in the development

of new technologies, additional expertise and industry-specific services.

Safety regulations

In the pharmaceutical industry, safety has the highest priority. To meet the

stringent international FDA, cGMP and GAMP standards, Hosokawa Micron has

developed a range of technically sophisticated systems with top quality surface

finishes, hygienic designs and which offer optimal cleaning.

Scaling up production

The pharmaceutical industry demands a wider range of equipment sizes than other

industries. Each phase of the product development process, from feasibility studies,

the development phase and on to full scale production, sets different requirements.

As a supplier, it is up to us to cater to these varying demands, which is why we offer

customers the flexibility of our three product ranges for scaling up production:

•Labscalebatchsizes:0.3-5litres

•Developmentscalebatchsizes:1-120litres

•Productionscalebatchsizes:25-10,000litres

Applications and processes:

•0.3-1litreActiveFreezeDryingsystem

•Multipurpose1-120litrevacuumdryingsystems

with multiple agitating mechanisms

•CIPvacuumdryingsystemfororallyadministered

active pharmaceutical ingredients (APIs)

•SIPconicalpaddledryingsystemforinjectable

antibiotics

•Thermalpost-vacuumdryingafterinitialspray

drying phase of API containing solvents

•Vacuumandoverpressuretightballsegmentvalve

in CIP and SIP execution

•Samplingdevicesforconicalbatchprocesses

in CIP and SIP execution

Services

•Globalorganisationandsupport

•Processdevelopment

•Processtestinginwell-equippedtestcentre

•Machinerental

•Scaleupsupportfromlabtoindustrialproduction

•Dedicatedprojectmanagement

•Adviceonvalidationdocumentationandprotocols,

DQ, IQ, OQ and assistance for PQ

•Systemsdesignaccordingtolatestdirectiveslike

cGMP, GAMP, FDA, ISPE, EHEDG, etc.

•Aftersalessupportfromourtechnicalservice

department

Ind

ustrie

s

Pharmaceutical industry

Antibiotics

Blood pressure regulation

Injectables

Fine Pharmaceuticals

Sterile intravenous medicines

Special care for

by Hosokawayour products

Drug discovery & development

Phase 1

Phase 2

Phase 3

Phase 4

Lab testing

Equipment development

Production of equipment

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The field of activity of the chemicals division is just as wide and diverse as the

overwhelming number of substances for which Hosokawa Micron offers drying

solutions. The drying process in the chemical industry is often critical, demanding

the highest of industry standards. Three important aspects worthy of special

attention are flexibility, energy efficiency and safety.

Flexibility

As product life cycles shorten, production facilities in the chemical industry need to

be equipped for making easy adjustments for the manufacture of alternative

products. Hosokawa Micron’s dryers and systems are designed for this very purpose:

for handling a wide range of different materials with varying product properties.

Energy efficiency

When it comes to energy efficiency, we fabricate our drying systems using the latest

technologies to precise specifications. This way, we can increase energy efficiency,

improve process optimisation and reduce operational costs. In fact, Hosokawa Micron’s

dryers are some of the most environmentally-friendly on the market.

Safety

Hazardous materials are synonymous with the chemical industry and drying them

requires specialist treatment. More importantly, these kinds of materials demand

stringent safety requirements. Needless to say, Hosokawa Micron always applies the

highest safety standards to all of its products and process systems.

Applications and processes

•Batchdryingofpolymers

•Continuousdirectdryingofaluminiumoxide

•Continuousdirectdryingofhighstrengthfibres

•Continuousflashdryingofagrochemicals

•Continuousflashdryingofflameretardants

•Continuousflashdryingofpigments

•Freezedryingofnanomaterials

•Vacuumdryingofcatalysts

•Vacuumdryingofchemicallyproducedtoner(CPT)

•Vacuumdryingofcropprotectingagents

•Vacuumdryingofmetalsalts

•Vacuumdryingofnuclearwaste

Services

•Globalorganisationandsupport

•Testingandvalidationinwell-equippedtestcentre

•Scaleupsupportfromlabtoindustrialscale

•Dedicatedprojectmanagement

•Useofourtestfacilities:challengeuswithyourdrying

problem, send us a sample of your product for us to test and

we will provide you with the optimal drying solution

Ind

ustrie

s

Chemical industry

Pigments

Catalysts

Dicalcium phosphate

Magnesium hydroxide

PE resin

Acrylates

CMC

Zeolite

Titanium dioxide

PVCMetal stearates

Copper hydroxide

Hosokawa

chemistryfeel the

Catalysts

Chemically Produced Toner (CPT)

Polymers

Agrochemicals

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Hosokawa Micron provides the minerals and metals industry with a wide range of

reliable and robust drying equipment, from single unit to turn key system. We offer

proven technologies and have the know-how and experience for a successful

operational concept for your product. Typical requirements for minerals and metals

include high productivity, reliability and low operational costs.

Productivity

In the mineral industry drying systems usually combine rotary dryers, flash dryers or

fluid-bed dryers in combination with a separate milling system. This involves several

units and multiple transfers between process steps. Hosokawa Micron offers a single

system capable of drying, grinding and classifying minerals and metals in one

compact operation, with close control of the product particle size and final moisture

content. We call this system the Drymeister (DMR).

Operational costs

The Drymeister (DMR) combines a high temperature inlet with a relatively low

temperature outlet. Optimal dispersion ensures that the product takes over the heat

of the drying gas quickly, leading to smaller sized drying systems and less energy

consumption per kilogram. An interesting advantage here is the resulting reduction

in operational costs. For small quantities of metals and minerals, we recommend the

vacuum batch dryer.

Reliability

Hosokawa Microns drying systems have a global reputation of high reliability. We

offer state-of-the-art technology that has proven to be highly efficient and extremely

reliable. Every system is engineered for high performance with maximal durability

and minimal downtime. To ensure this, we always apply adequate measures for

maximum safety, for your product, the operator and the environment.

Applications and processes

•Continuousflashdryingofbentoniteandkaolin

•Continuousflashdryingofgypsum

•Continuousflashdryingofsilicates

•Continuousflashdryingofmetalcarbides

•Vacuumdryingofmetalpowders

•Continuousdirectdryingofbarite

Services

•Globalorganisationandsupport

•Processdevelopment

•Processsimulationtoproveproductqualityandprocess

functionality

•Contractmanufacturing

•Useofteststationflashdryer(DMR)withaninlet

temperature up to 650 ºC

•Useofteststationbatchhightemperaturevacuumdryer

(>300 ºC)

Minerals & Metals industry

TalcZinc oxide

Zircon sand

Aluminum oxide

Magnesium oxide

Lithium powder

Gypsum

GraphiteFillers

Aluminum silicates

Rare earths

BentoniteFeldspar

Kaolin

Ceramics

Quartz

Precious metals

Calcium carbonate

Hosokawa,rock solid

solutions

Metal powders

Zeolite(cat litter)

Precious metals

Calcium carbonate

Ind

ustrie

s

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CONTACT

THe NeTHeRlANDS

Hosokawa Micron B.V.

Gildenstraat 26

PO Box 98

7000 AB Doetinchem, NL

Phone: +31 (0)314 37 33 33

Fax: +31 (0)314 37 34 56

E-mail: [email protected]

Internet: www.hosokawamicron.nl

TeAM FOOD/PHARMA

Phone: +31 (0)314 37 34 62

Fax: +31 (0)314 37 34 91

E-mail: [email protected]

TeAM CHeMICAlS/MINeRAlS/MeTAlS

Phone: +31 (0)314 37 34 60

Fax: +31 (0)314 37 35 22

E-mail: [email protected]

TeAM SeRVICe

Phone: +31 (0)314 37 33 74

+31 (0)314 37 33 75

Fax: +31 (0)314 37 34 31

E-mail: [email protected]

After office hours

Phone: +31 (0)314 37 35 05

H O S O K A W A M I C R O N G R O U P W O R L D W I D E

Hosokawa is the world’s largest provider

of processing systems for the field of

powder and particle processing. Renowned

names such as Alpine, Bepex, Micron,

Mikro, Stott, Vitalair and Vrieco-Nauta®

are all included in the Group’s range.

Regardless of the size, i.e. production-scale

systems, pilot systems or laboratory

equipment, Hosokawa’s products and

technologies are used in numerous process

stages, for example during mixing, drying,

agglomeration, containment, filling,

metering, size reduction and classification.

Hosokawa Sales Office

Engineering / Manufacturing / Test Centre

• HM B.V. (The Netherlands)

• H. Alpine (Germany)

• H. Bepex (Germany)

• HM Ltd. (UK)

• HM SA (France)

• HM OOO (Russia)

• HM MENA (Jordan)

• HM Polymer Systems (USA)

• HM Powder Systems (USA)

• HM Powder Systems (Mexico)

• HMS (China)

• HMI (India)

• HMM (Malaysia)

• HMK (South Korea)

• HOSOKAWA MICRON CORPORATION

Headquarters

No. 9, 1-Chome, Shoudai-Tajika,

Hirakata, Osaka, 573-1132

Japan

Tel: +81-72-855-2704

Fax: +81-72-855-2561

PROCESS TECHNOLOGIES FOR TOMORROWSM38 39

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Hosokawa Micron B.V. is a member of the Hosokawa Micron Group, responding

to global needs through emphasis on materials science and engineering.

The Group is an international provider of equipment and technology for

powder and particle processing, plastics processing and confectionery products.

The Group maintains facilities for research, engineering, manufacturing and

service in each of the world’s major industrial markets.

© 2013 Hosokawa Micron B.V. Doetinchem, The Netherlands